Device for the automatic straightening of elongate material to be straightened, and method therefor

Abstract

The invention relates to a device (V) for the automatic straightening of elongate material to be straightened (1, 2), such as wire, which is fed to a welding system for the production of objects from welded longitudinal wires and transverse wires, such as reinforcing mesh or the like, comprising at least one skin pass device (3) with a plurality of straightening rollers (4) for straightening the material to be straightened (1, 2), wherein the skin pass device (3) has measuring devices for measuring measurement variables during a straightening operation in order, on the basis of measured measurement variables, to adjust straightening rollers (4) of the skin pass device (3) for automatic straightening of the material to be straightened (1, 2) and to achieve straightening of the material to be straightened (1, 2). According to the invention, a plurality of straightening roller groups (5, 6) are provided for straightening a plurality of strands of material to be straightened that run in parallel, wherein straightening rollers (4) of the straightening roller groups (5, 6) can be adjusted independently of one another. The invention further relates to a method that is carried out by a corresponding device (V).

Description

[0001] Device for automatically straightening longitudinally stretched material and method therefor

[0002] The invention relates to a device for automatically straightening longitudinally extended straightening material such as wire, which is fed to a welding system for producing objects from welded longitudinal wires and transverse wires such as reinforcement mats or the like, comprising at least one dressing device with a plurality of straightening rollers for straightening the straightening material, wherein the dressing device has measuring devices for measuring measured variables during straightening in order to suitably adjust straightening rollers of the dressing device for automatically straightening the straightening material on the basis of measured measured variables and to achieve straightening of the straightening material.

[0003] Furthermore, the invention relates to a method for automatically straightening straightening material such as wire, which is fed to a welding system for producing objects from longitudinally welded longitudinal bars and cross bars such as reinforcement mats or the like, in particular with a device of the above type, wherein the straightening material is straightened with at least a dressing device with a plurality of straightening rollers for straightening the straightening material, wherein measured variables are measured during the straightening in order to suitably adjust straightening rollers of the dressing device for automatically straightening the straightening material on the basis of measured parameters and to achieve straightening of the straightening material.

[0004] The production of mats from welded longitudinal and transverse elements requires starting material that meets a predetermined straightness requirement. This applies, for example, to the manufacture of reinforcement mats, but also to other products such as mats for fences, which are produced by welding longitudinal and transverse elements, in particular wires or rods. For this purpose, a corresponding welding system is usually equipped upstream of devices with which the longitudinal and transverse elements to be welded can be prepared. This includes, in particular, a reel for wound starting material, one or more subsequent straightening units for straightening the starting material, and a cutting device for cutting the straightened starting material to the desired length. After the cutting process with the cutting device, the starting material can be used for the actual welding process.

[0005] During straightening, the raw material passes through a dressing device with a large number of straightening rollers. The rollers are adjusted so that the raw material passing through the dressing device is sufficiently straightened.

[0006] As in other areas of technology, efforts are being made to ensure that the process of straightening material for a downstream welding device can be recorded and controlled as accurately as possible. In this context, WO 2020 / 172694 A2 discloses measuring individual parameters in order to continuously adapt at least one straightening roller based on the measured parameters so that a predetermined straightening of the material to be straightened is achieved. Possible measured parameters are the magnitude and direction of the forces acting on the straightening rollers themselves and / or the temperature of the material before and after passing through the arrangement of straightening rollers and / or the position of the material following a straightening roller. The data recorded through corresponding measurements are entered into a model and evaluated so that the ongoing adaptation or adjustment of the straightening rollers can take place.

[0007] A device according to WO 2020 / 172694 A2 and the method disclosed in this document have proven highly effective in practice. However, the inventors have recognized that, particularly with force measurement, which according to the prior art described is carried out in the axes on which the straightening rollers are mounted, it is a significant disadvantage that only a single track can be straightened. Based on this, the inventors have further recognized that this disadvantage can be eliminated if several straightening roller groups are provided for straightening several parallel strands of material to be straightened, with the straightening rollers of the straightening roller groups being adjustable independently of one another.It was thus recognized that multiple strands of straightened material can be processed in parallel with simultaneous acquisition of measurement data relevant for adjusting straightening rollers and a predetermined straightening process if the straightening rollers of the straightening roller groups are arranged in the same device but decoupled from each other. The object of the invention is to increase productivity in the provision of straightened material without compromising quality with regard to specified quality criteria for straightening.

[0008] On the basis of the findings obtained, this task is solved if, in a device of the type mentioned at the beginning, several straightening roller groups are provided for straightening several parallel running straightening material strands, wherein straightening rollers of the straightening roller groups can be adjusted independently of one another.

[0009] Due to the possibility of parallel guiding of straightening material strands, productivity can be increased without having to accept any loss of quality in terms of straightening.

[0010] Preferably, the at least one dressing device has measuring devices for measuring forces occurring on straightening rollers. The measuring devices are then suitably configured for continuous force measurement. This allows for simple and reliable implementation to measure a measured variable required for straightening the material to be straightened and a model for this. However, alternatively, the options known from the prior art for detecting a temperature of the material to be straightened or a position of the material to be straightened after a straightening roller are also possible. If force measurement is provided, this can be carried out using strain gauges in an axis on which a straightening roller is mounted, as is evident from the document WO 2020 / 172694 A2, the content of which is hereby incorporated with regard to the determination of measured variables.

[0011] Typically, several dressage devices are provided, namely a so-called pre-dressage device with horizontally arranged straightening rollers and a so-called main dressage device, which is located downstream of the pre-dressage device and has vertically arranged straightening rollers. The inventive concept is particularly useful in a main dressage device.

[0012] The rollers can be mounted on axes without a drive. This means that the individual straightening rollers are not connected to a rotary drive, but are driven forward by suitable feed rollers. When using wire as the straightening material, typical wire diameters range from 2 mm to 25 mm, especially 4 mm to 20 mm.

[0013] The straightening roller groups, which have straightening rollers that can be adjusted independently of one another, can be positioned in various ways. It is particularly preferred that several, in particular two to five, dressing devices are provided, each with a straightening roller group for one strand of straightened material, wherein the dressing devices are arranged offset from one another. In particular, these can be dressing devices for a main dressing. In order to measure at least one measured variable, measuring devices can be provided in the axes for the straightening rollers, in particular force measuring devices such as strain gauges or the like, including the necessary means for transmitting measured data. An offset arrangement can be achieved by arranging the dressing devices one after the other, in particular one after the other in a common horizontal plane.For example, if two wire tracks are provided that are to be straightened in parallel, a second wire runs freely while a first wire is being straightened, and vice versa. In this case, the straightening devices are arranged and designed such that as soon as one straightening device is engaged, the parallel strands of straightened material run freely. Thus, only one straightening device is engaged, the others are not.

[0014] A staggered arrangement is also possible if several strands of material are guided underneath each other. In this case, simultaneous processing and straightening is possible, viewed in the feed direction.

[0015] Other types of displacement are also conceivable. In principle, however, with an increasing number of straightening strands, either the length of the system (sequence arrangement) or the height of the system (superimposed arrangement) increases. Therefore, in a further aspect of the invention, it can be preferred to provide a dressing device with several straightening roller groups, wherein the straightening rollers of the straightening roller groups are positioned on common axes, wherein at least some of the straightening rollers positioned on common axes can each be adjusted separately on the respective axis. This variant enables a space-saving implementation of the inventive concept. For this purpose, the individual straightening rollers, which are positioned parallel on a common axis, can be adjusted independently of one another, so that parallel straightening strands can also be treated separately.In this context, it is recommended that the measuring devices be located in or near the bearings of the straightening rollers. This is because the axis is common to the individual parallel-mounted straightening rollers and therefore cannot be used for differentiating, for example, occurring forces, or for control purposes.

[0016] In this variant, separate adjustment can be achieved in particular by the axle comprising an outer hollow shaft, within which another shaft is guided, projecting beyond the hollow shaft. The hollow shaft and the additional shaft each carry an eccentric support for a roller at their ends. Using suitable drives, the hollow shaft and the additional shaft can be rotated, allowing the heights of the rollers to be adjusted separately via the eccentric supports.

[0017] A device according to the invention can in principle be used in any process in which several strands of straightened material are to be straightened according to predetermined quality criteria for straightening. As a rule, a device according to the invention is part of a system, in particular a system in or with which wire, in particular cut-to-length wire, is processed. However, it is particularly preferred for the device according to the invention to be used in a welding system for producing mats from welded longitudinal wires and transverse wires, since corresponding mats can then be produced with high quality if the starting material used meets high straightening requirements. For this purpose, a cutting device for cutting the straightened wire to length can be connected to the device according to the invention.

[0018] In a further aspect, the invention relates to a method of the type mentioned at the outset, wherein a plurality of straightening material strands are straightened in parallel with a plurality of straightening roller groups, wherein straightening rollers of the straightening roller groups are adjusted independently of one another.

[0019] The advantages explained for the device according to the invention apply analogously to a method according to the invention. In particular, a method according to the invention makes it possible to process wire provided in reels in parallel in several tracks without having to accept any quality losses with regard to the straightness of deflected wires, struts, or the like. The method is preferably carried out using a device according to the invention.

[0020] It is particularly preferred that forces are measured as a measurement variable. Using corresponding measurement data, which, as mentioned, are advantageously recorded in or near the bearings of individual straightening rollers, a model can be continuously supplied with data, after which the adjustment of at least one straightening roller can be calculated from the data. Alternative measurement variables can also be recorded, for example a temperature of individual strands of straightened material at specific positions during the straightening process and / or a position of the starting material during the straightening process. For the latter variants, non-contact measurement methods are advantageously used, in particular optical measurement methods. In terms of device, suitable equipment such as cameras, lasers or the like, together with suitable peripherals for data transmission to supply the model, can be provided.

[0021] Advantageously, the straightening strands are straightened horizontally offset in a feed direction in a plane. For example, the individual straightening strands can be straightened one after the other in the feed direction, with one dressing device engaged at a time, while the other straightening strands run freely. In this case, all straightening strands are located in the same horizontal plane. It is also possible for the individual straightening strands to be straightened using groups of straightening rollers arranged one below the other. In this case, the straightening strands can be straightened simultaneously.

[0022] Alternatively, it is also possible for the strands to be straightened to be straightened using straightening roller groups with parallel straightening rollers mounted on a common axis, with parallel straightening rollers being adjusted independently of one another. Since the individual parallel straightening rollers can be moved and thus adjusted independently of one another, a staggered arrangement is unnecessary, which allows the method to be carried out in a small space and thus in a space-saving manner. Further features, advantages, and effects of the invention will become apparent from the exemplary embodiments presented below. The drawings, to which reference is made, show:

[0023] Fig. 1 shows a diagram for measuring parameters on a wire to be straightened;

[0024] Fig. 2 shows a device according to the invention;

[0025] Fig. 3 shows a further device according to the invention; Fig. 4 shows a pair of straightening rollers for two tracks.

[0026] Fig. 1 shows a straightening device 3, as known from WO 2020 / 172694 A2. The straightening device 3 has a straightening roller group 5 with a plurality of straightening rollers 4, wherein some of the straightening rollers 4 are mounted above a material to be straightened and some of the straightening rollers 4 are mounted below the material to be straightened, each separately on an axis. The material to be straightened can, in particular, be a wire, which is straightened and then separated using a cutting device, so that longitudinal bars and transverse bars can be provided as starting material for a welding device. The welding device can, in particular, be used to produce mats from welded longitudinal bars and transverse bars.

[0027] In a device according to Fig. 1, certain measured variables of the material to be straightened and / or the straightening rollers 4 are recorded in order to be able to draw conclusions about the quality of the straightening and thereby, in particular, to adjust individual straightening rollers 4 appropriately so that quality requirements for straightening are met. The measured variables can be, in particular, forces acting on the straightening rollers 4 or the associated axes, a temperature of the material to be straightened along the straightening section or track, and / or other measured variables such as deformations of the material. Preferably, several of these measured variables are recorded. The data from the measured variables flow into a model with which the data is evaluated. Based on the data evaluation, the adjustment of individual straightening rollers 4 is continuously adjusted so that the straightening process is continuously optimized in order to meet specified quality criteria for straightening. A device according to Fig.1 has proven itself in practice, but has the disadvantage that only a single track or strand of material can be straightened. Multiple tracks would require multiple devices.

[0028] Fig. 2 shows a device V according to the invention which solves the above problem. The device V comprises a plurality of dressing devices 3. Each of the two dressing devices 3 comprises a straightening roller group 5, 6. Each of the straightening roller groups 5, 6 again comprises, similar to Fig. 1, a plurality of straightening rollers 4, each of which is mounted on an axle without a drive. At least some of the straightening rollers 4 are displaceable so that adjustment can take place depending on measured variables. The method from WO 2020 / 172694 A2 explained with reference to Fig. 1 can be used here. It is particularly preferred that various measured variables are incorporated into the model in order to enable the most reliable control possible with regard to adjustment of the straightening rollers 4.

[0029] As can be seen from Fig. 2, with the device V two tracks or straightening material 1, 2 can be straightened simultaneously and in parallel through the device V. This increases process efficiency. As can be seen, the straightening material 1, 2 runs freely alternately. This means that at a certain feed position one dressing device 3 is engaged while the other dressing device 3 is not engaged and vice versa. In other words: in the feed direction a part of the straightening material 1, 2 or one track is straightened, while the part of the straightening material 1, 2 running parallel in the feed direction or the other track is not straightened. The device V thus allows several tracks running in a horizontal plane to be straightened with a single device V.

[0030] A device V according to Fig. 2 requires additional space for the additional dressing device 3 (and each further dressing device 3). To avoid this, a solution according to Fig. 3 can be found. The device V according to Fig. 3 also comprises a dressing device 3 which is designed with an analogous arrangement of straightening rollers 4 in straightening roller groups 5, 6 as in Fig. 1, although the individual axes 8 are equipped with two straightening rollers 4. Thus, on the device V according to Fig. 3, two tracks can be straightened in parallel at the same time. However, a measurement of measured variables cannot be carried out as with a device V according to Fig. 2 (e.g. strain gauges in the axes) if forces are to be measured, since both straightening rollers 4 are positioned on a common axis 8.To make this possible, the two straightening rollers 4 are initially split and then adjustably mounted on their respective axles 8 using their own spindle drives. For this purpose, the axles 8 comprise an outer hollow shaft, inside which another shaft is guided, projecting beyond the hollow shaft, and wherein the hollow shaft and the further shaft each have an eccentric support for a roller at their ends. The hollow shaft and the further shaft can be rotated using spindle drives provided, and the heights of the rollers can thus be adjusted separately from one another using the eccentric supports. This initially makes it possible for different strands of straightened material to be subjected to different forces. Forces can then be measured in or near the bearings of the corresponding straightening roller 4. For this purpose, as shown in Fig.4, suitable sensors are positioned in the straightening roller area 7, which are configured to communicate with a data processing device for acquiring data from measured variables. The data processing device performs a continuous or quasi-continuous evaluation of the measured data, the results of which are in turn used to adjust individual straightening rollers 4 appropriately with respect to a quality criterion for straightening.

[0031] With a device V according to the invention and a corresponding method, a high level of efficiency and, at the same time, a high quality of the straightened material 1, 2 can be achieved with comparatively simple means either by offsetting straightening roller groups 5, 6 in the feed direction or transversely to the feed direction while simultaneously ensuring independence of the adjustment of individual straightening rollers 4 of the straightening roller groups 5, 6.

Claims

Patent claims 1. Device (V) for automatically straightening longitudinally extended straightening material (1, 2) such as wire, which is fed to a welding system for producing objects from welded longitudinal wires and transverse wires such as reinforcement mats or the like, comprising at least one dressing device (3) with a plurality of straightening rollers (4) for straightening the straightening material (1, 2), wherein the dressing device (3) has measuring devices for measuring measured variables during straightening in order to suitably adjust straightening rollers (4) of the dressing device (3) for automatically straightening the straightening material (1, 2) on the basis of measured measured variables and to achieve straightening of the straightening material (1, 2), characterized in that a plurality of straightening roller groups (5, 6) are provided for straightening a plurality of parallel strands of straightening material, wherein straightening rollers (4) of the straightening roller groups (5, 6) can be adjusted independently of one another.

2. Device (V) according to claim 1, characterized in that the at least one dressage device (3) has measuring devices for measuring forces occurring on straightening rollers (4).

3. Device (V) according to claim 2, characterized in that the measuring devices are designed for continuous force measurement.

4. Device (V) according to one of claims 1 to 3, characterized in that the straightening rollers (4) are designed without a drive.

5. Device (V) according to one of claims 1 to 4, characterized in that several, in particular two to five, dressing devices (3) are provided, each with a straightening roller group (5, 6) for each strand of straightened material, wherein the dressing devices are arranged offset from one another.

6. Device (V) according to claim 5, characterized in that measuring devices are provided in the axes for the straightening rollers (4) for measuring at least one measured variable.

7. Device (V) according to claim 5 or 6, characterized in that the training devices (3) are arranged one after the other, in particular one after the other in a common horizontal plane.

8. Device (V) according to claim 7, characterized in that the dressing devices (3) are arranged and designed in such a way that as soon as a dressing device (3) is engaged, the parallel strands of straightened material run freely.

9. Device (V) according to one of claims 1 to 4, characterized in that a dressage device (3) with several straightening roller groups (5, 6) is provided, wherein straightening rollers (4) of the straightening roller groups (5, 6) are positioned on common axes (8), wherein at least some of the straightening rollers (4) positioned on common axes (8) are each separately adjustable on the respective axis.

10. Device (V) according to claim 9, characterized in that the measuring devices are arranged in or in the region of bearings of the straightening rollers (4).

11. Welding system for producing mats from welded longitudinal wires and transverse wires, comprising a device (V) according to one of claims 1 to 10.

12. A method for automatically straightening material to be straightened (1, 2), such as wire, which is fed to a welding system for producing objects from welded longitudinal bars and transverse bars, such as reinforcement mats or the like, in particular with a device (V) according to one of claims 1 to 10, wherein the material to be straightened (1, 2) is straightened using at least one dressing device (3) with a plurality of straightening rollers (4) for straightening the material to be straightened (1, 2), wherein measured variables are measured during straightening in order to suitably adjust straightening rollers (4) of the dressing device (3) for automatically straightening the material to be straightened (1, 2) on the basis of measured measured variables and to achieve straightening of the material to be straightened (1, 2), characterized in that a plurality of strands of material to be straightened are straightened in parallel using a plurality of straightening roller groups (5, 6), wherein straightening rollers (4) of the straightening roller groups (5, 6) are adjusted independently of one another.

13. Method according to claim 12, characterized in that forces are measured as a measured variable.

14. Method according to claim 12 or 13, characterized in that the strands of material to be straightened are straightened horizontally offset in a plane in a feed direction.

15. Method according to claim 14, characterized in that the strands to be straightened are straightened by straightening roller groups (5, 6) with straightening rollers (4) mounted parallel on a common axis, wherein the parallel straightening rollers (4) are adjusted independently of one another.

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